User manual CANNONDALE 2003 E440, C440, X440, S440 PARTS CATALOG

[. . . ] [. . . ] COMPRESSION ADJUSTER O-RING COMPRESSION SHIM SET FORK COMPRESSION PISTON FORK COMPRESSION PISTON O-RING COMPRESSION PISTON SHIM COMPRESSION PISTON WAVE WSHR FRONT WHEEL AXLE PINCH BOLT FORK INNER TUBE ASSY-LEFT FORK GUARD BOLT FORK GUARD SET FORK INNER TUBE BUSHING DAMPING CARTRIDGE TUBE LOCKNUT WASHER MID VALVE SHIM SET FORK REBOUND PISTON RING FORK REBOUND PISTON REBOUND SHIM SET REBOUND ADJUSTER BODY REBOUND ADJNEEDLE SPRING REBOUND ADJ NEEDLE REBOUND ADJ NEEDLE O-RING FORK TOP OUT SPRING FORK DAMPER ROD FORK TOP OUT SPRING WASHER FORK DAMPER ROD BUSHING FORK DAMPER ROD SLEEVE O-RING FORK DAMPER ROD SLEEVE DAMPING CARTRIDGE TUBE CAP DAMPER ROD CIRCLIP HYDRAULIC STOP COLLAR CIRCLIP FORK HYDRAULIC STOP FORK HYDRAULIC STOP COLLAR FORK SPRING GUIDE REBOUND ADJUSTER ASSY. REBOUND ADJUSTER O-RING FORK REBOUND ADJUSTER ROD FORK WIPER FORK SEAL RETAINING CIRCLIP FORK SEAL FORK SEAL RETAINING WASHER FORK OUTER TUBE BUSHING SLEEVE FORK OUTER TUBE BUSHING FORK OUTER TUBE BUSHING CIRCLIP FORK OUTER TUBE FORK OUTER TUBE DECAL FORK SPRING FORK SPRING WASHER FORK SPRING SPACER FORK OUTER TUBE CAP O-RING FORK OUTER TUBE CAP FORK AIR BLEED SCREW O-RING FORK AIR BLEED SCREW FORK OUTER TUBE CAP NUT X S E EA ER C DESCRIPTION MODEL X X X OPTIONAL STANDARD OPTIONAL NOTES FRONT FORK PARTS LIST 8 Steering Head 8 6* 8* 11 10 2 3 7 13 5* 9 12 8* 8 4 8 1 13 2 5000760 12 2 5000722 11 1 5000717 10 1 5000170 9 1 5000174 * 4 5000728 8 12 5000100 7 2 5000101 * 2 5002537 6 2 5000534 * 2 5002533 5 2 5000533 4 1 012-5002097 3 1 5000001B 2 1 ITEM QTY DEALER PART NO REQD NUMBER HEA DSET BEA RING, UPPER HEA DSET SEA L, UPPER STEERER WASHER SLOTTED LOCKNUT STEERER NUT X FHB, M8X55 mm X FHB, M8X45 mm FHB, M12X35 mm, NLK X X CLA MP, HA NDLEBA R, UPPER CLA MP, HA NDLEBA R, UPPER X X CLA MP, HA NDLEBA R, LOWER CLA MP, HA NDLEBA R, LOWER LOWER TRIPLE CLA MP A SSY UPPER TRIPLE CLA MP FRNT BRKE GDE, UPPER FRNT BRKE GDE, LOWER ER C DESCRIPTION X X X X X X X X X X X X FOR USE W/ HANDGUARD BRCKT SEE FRONT BRA KE GUIDE, UPPER SEE FRONT BRA KE GUIDE, LOWER NOTES X S E EA MODEL STEERING HEAD PARTS LIST 9 Front Brake Guides 5 4 6 7 4 2 3 2 1 4 7 2 5000822 6 1 5001270 5 1 5000038 4 4 5001013 3 1 5002261 2 2 5000535 1 1 5002263 ITEM QTY DEALER PART NO REQD NUMBER BRAKE LINE GUIDE TOPHAT BRAKE GUIDE CLAMP BRAKE GUIDE MOUNT ASSY FLNG HD BLT, M6X16, NLK FRONT BRAKE GUIDE MOUNT, UPPER FRONT BRAKE GUIDE FRONT BRAKE GUIDE MOUNT, LOWER DESCRIPTION XX X FOR USE W/ HEADLIGHT X S E EA ER C MODEL NOTES BRAKE GUIDES PARTS LIST 10 Handlebar & Controls List 23 2 18 1* 56 3 4 7 8 19 20 9 10 12 13 16 * 24 32 11 22 45 41 35 40 39 15 * 36 37 14 21 17 * 42 25 43 33 38 34 26 * 31 44 28 27 46 29 30 47 11 47 2 5000728 46 2 5001927 45 AR 5002385 44 1 5002373 43 1 5002374 42 1 5002375 41 2 5002376 40 1 5002377 39 1 5002378 38 1 5002379 37 1 5002380 36 1 5002381 35 1 5002382 34 1 5002383 33 1 5002384 32 1 5002386 31 1 5002387 30 2 5002538 29 2 5002539 28 2 6000252 27 2 6000277 * 1 5002519 26 1 5002215 25 1 5001808L 24 1 5001808 23 4 5000379 22 1 5002364 21 1 5000131-01 20 1 5002363 19 1 5000437 18 1 5001274-04 * 1 6001180 * 1 5002262 17 1 5000317 * 1 5002518 * 1 5002454 16 1 5000120 * 1 5002372S 15 1 5002372 14 1 5002095 13 1 5000125 12 2 5000786 11 1 5000123 10 1 5001590 9 1 5001369 8 2 5001368 7 1 5001367 6 1 5001366 5 1 5001365 4 1 5000488 3 1 5000124 2 1 5000121 * 1 5002252 1 1 5000474 ITEM QTY DEALER PART NO REQD NUMBER X X X X X X X X X X X X X X X X X X X XX XX X XX X XXXX X X S E EA ER C MODEL FHB M8X55 mm FHB M5X20 mm HYDRAULIC CLUTCH OIL, 16 oz. PAD SET NOT INCLD X FRONT BRAKE CALIPER ASSEMBLY ER C DESCRIPTION NOTES FRONT BRAKE CALIPER PARTS LIST 15 Rear Brake Pedal 4 3 6 6 1 5 2 6 2 5000375 5 1 5000399 4 1 5000413 3 1 5000109 2 1 5000112 1 1 5001226 ITEM QTY DEALER PART NO REQD NUMBER SEAL, 15X21X3 BOLT, BRAKE PEDAL RR BRAKE COTTER PIN BRAKE PEDAL YOKE PIN SPRING, BRAKE PEDAL REAR BRAKE PEDAL X S E EA ER C MODEL DESCRIPTION INCLUDED IN 5001226 INCLUDED IN 5001226 NOTES REAR BRAKE PEDAL PARTS LIST 16 Rear Brake Master Cylinder 12 8 13 13 10 16 7 12 1 13 9 13 6 15 2 5 1 3 1 4 2 14 2 2 11 16 1 5000434 15 1 5001013 14 2 5000126 13 4 5001549 12 2 5000538 11 1 5001268 10 1 5000537 9 1 5002285 8 AR 5000268 7 1 5000085 6 1 5000104 5 1 5000105 4 1 5000107 3 1 5000267 2 1 5000106 1 1 5000086 ITEM QTY DEALER PART NO REQD NUMBER NUT, FLANGE, M6 FLANGE HEAD BOLT, M6 X 16 SHCS, M8 X 20 CRUSH WASHER BRAKE LINE BANJO BOLT RR BRAKE MSTR CYL GUARD REAR BRAKE LINE RR BRAKE MSTR CYL ASSY NISSIN BRAKE GREASE, 2 GRAM RR BRAKE RESERVOIR ASSY RR BRAKE RESERVOIR HOSE KIT RR BRAKE MSTR CYL ELBOW KIT RR BRAKE MSTR CYL BOOT RR BRAKE MSTR CYL PISTON CIRCLIP RR BRAKE MSTR CYL PUSHROD KIT RR BRAKE MASTER CYL KIT X S E EA ER C MODEL DESCRIPTION AS REQUIRED NOTES REAR BRAKE MASTER CYLINDER PARTS LIST 17 Rear Brake Caliper 1 3 8 5 2 9 10 4 6 10 1 5000082 9 1 5000052 8 1 5000055 7 AR 5000268 6 1 5000050 5 1 5000081 4 1 5000096 3 1 5000098 2 1 5000091 1 1 5000083 ITEM QTY DEALER PART NO REQD NUMBER REAR BRAKE PAD SET SLIDE PIN BOOT - LARGE BRAKE CALIPER BLEEDER KIT NISSIN BRAKE GREASE, 2 GRAM SLIDE PIN BOOT - SMALL REAR BRAKE CALIPER ASSEMBLY REAR BRAKE CALIPER BRACKET REAR BRAKE PAD PIN KIT REAR BRAKE PAD SPRING REAR BRAKE CALIPER PISTON KIT X S E EA ER C MODEL DESCRIPTION AS REQUIRED NOTES REAR BRAKE CALIPER PARTS LIST 18 Mainframe 1 18 * 7 19 13 11 14 4 5 3 2 9 10 8 17 16 15 12 6 19 1 5002409 * 1 5002331 18 1 5002198 17 1 5002071 16 2 5002069 15 2 5000482 14 1 5000487 13 1 5000828 12 1 5000140 11 1 5001184 10 1 5000863 9 1 5002068 8 1 5001374 7 1 5001434-03 6 2 5000524 5 1 5000233-E 4 4 5000190 3 1 5001593 2 5 5000888 1 1 201-5002100 ITEM QTY DEALER PART NO REQD NUMBER CLAMP, ONE-EARED, STEPLESSS, 19. 8 HOSE, BREATHER, FRAME HOSE, BREATHER, FRAME OIL LEVEL SIGHT WINDOW FHCS, M10X1. 5X16 O-RING, 2-011 O-RING, 2-012 O-RING, 2-016 LOCKNUT, M8 FLNG HD BLT, M6X12, NLK FLNG HD BLT, M8X40, NYLK FHB, M8X60 mm CHAIN ROLLER SPACER OIL FILL CAP DRIVE CHAIN ROLLER ENGINE OIL FITTING THREADED INSERT, M8 INSERT, M8 RIVNUT, M6 MAIN FRAME SUB ASSY X S E EA ER C MODEL DESCRIPTION GREEN STICKER INCLUDED IN 5002100 INCLUDED IN 5002100 INCLUDED IN 5002100 NOTES MAINFRAME PARTS LIST 19 Subframe 1 10 * 9 12 * 11 14 3 4 13 8 7 2 5 6 15 4 5000192 14 1 6000341 13 1 5001013 * 1 5002520 12 1 5002615 11 2 5000189 * 2 5000093 10 2 5000423 9 1 6000378 8 1 5002228 7 2 5002234 6 2 5002326 5 2 6000116 4 2 5000139 3 1 5001593 2 7 5000888 1 1 201-5002103 ITEM QTY DEALER PART NO REQD NUMBER FLAT WASHER, M6 NUT, LOCK, M6 FHB M6X16 mm X X X X X VOLTAGE RECTIFIER/REGULATOR X VOLTAGE RECTIFIER/REGULATOR THREADED INSERT, M6 X X X X X FLANGE-HEAD BOLT, M6X25 X FLANGE-HEAD BOLT, M6X50 X SPACER, REAR BRAKE RESERVOIR SEAT LATCH WEAR PLATE BHCS, M3X5 mm ISOLATION BLOCK BOLT, SHOULDER, M8X15 mm SHLDR SS, M10X12, NLKZC THREADED INSERT, M8 RIVNUT, M6 SUBFRAME WELDMENT X S E EA ER C DESCRIPTION MODEL GROUND GROUND INCLUDED IN 201-5002103 INCLUDED IN 201-5002103 INCLUDED IN 201-5002103 INCLUDED IN 201-5002103 INCLUDED IN 201-5002103 NOTES SUBFRAME PARTS LIST 20 Frame Rail & Skid Plate 5 8 1 2 3 5 7 6 9 4 * 11 10 11 4 5001531 10 4 5001013 * 1 5001792-04 9 1 5000156-02 8 2 5000612 7 4 6000391 6 2 5000527 5 6 5000190 4 4 5001967 3 2 5000888 2 1 201-5002102 1 1 201-5002101 ITEM QTY DEALER PART NO REQD NUMBER TOP HAT WASHER, PLASTIC FLANGE-HEAD BOLT, M6X16 X X X X SKID PLATE, ALUM X SKID PLATE, PLASTIC FLNG HD BLT, M8X35, NYLK SHCS, M8x30mm NYLK FLNG HD BLT, M10X90, NLK THREADED INSERT, M8 INSERT, M6 RIVNUT, M6 FRAME RAIL, LEFT FRAME RAIL, RIGHT X S E EA ER C DESCRIPTION MODEL X FOR USE W/ PLASTIC SKID PLATE INCLUDED IN 201-5002101/5002102 INCLUDED IN 201-5002101/5002102 INCLUDED IN 201-5000521/5000522 NOTES FRAME RAIL PARTS LIST 21 Footpegs 1 6 7 * 2 4 3 5 * 2 5000136 X X X X BHCS, M10X30, NYLKZNC 7 2 5001264 XX BHCS, M10X25, NYLKZNC 6 1 5001919 FOOTPEG BRACKET 5 1 5000526 FOOTPEG, LEFT 4 1 5000713 FLAT WASHER, M8 3 1 5000400 COTTER PIN, 2. 5X20 2 1 5000985 FOOTPEG SPRING, LEFT 1 1 5000986 FOOTPEG PIVOT PIN ITEM QTY DEALER PART X S E EA ER C DESCRIPTION NO REQD NUMBER MODEL USE W/ KICKSTAND NOTES LEFT FOOTPEG PARTS LIST 1 6 5 2 4 3 7 7 2 5001264 6 1 5001919 5 1 5002286 4 1 5000713 3 1 5000400 2 1 5000984 1 1 5000986 ITEM QTY DEALER PART NO REQD NUMBER BHCS, M10X25, NYLKZNC FOOTPEG BRACKET FOOTPEG, RIGHT FLAT WASHER, M8 COTTER PIN, 2. 5X20 FOOTPEG SPRING, RIGHT FOOTPEG PIVOT PIN X S E EA ER C MODEL DESCRIPTION NOTES RIGHT FOOTPEG PARTS LIST 22 Kickstand 3 2 4 5 1 5 1 5001891 4 1 5001892 3 1 5001893 2 1 5001882-02B 1 1 5001882-02A ITEM QTY DEALER PART NO REQD NUMBER KICKSTAND PIVOT BOLT KICKSTAND TENSION SPRING NUT, HEX, LOCK, M10 KICKSTAND MOUNT KICKSTAND LEG X S E EA ER C MODEL DESCRIPTION NOTES KICKSTAND PARTS LIST 23 Swingarm 31 * 33 1 5000421 32 4 5000757 31 2 5000755 30 2 5000756 29 2 5000758 28 2 5000759 27 2 5000754 26 4 5001470 25 1 5000115 24 1 5000716 23 1 5000541 22 1 5002298 21 1 5000088 20 1 5000231 19 1 5000070 18 1 252-5002104 17 1 5000114 16 1 5001939 15 2 5000144 14 2 5000145-04 13 1 5000143-07 12 1 5000142-13 11 1 5001008 10 1 5000439 * 2 5000862 9 2 5000423 8 1 5001184 7 2 5001957 6 2 5000434 5 4 5001468 4 4 5000726 3 1 5000189 2 1 5000152 1 1 5000814 ITEM QTY DEALER PART NO REQD NUMBER HEX HEAD SET SCREW M8X50 mm SWINGARM PIVOT THRUST WASHER SWINGARM PIVOT BRNG, INR SPCR SWINGARM PIVOT NEEDLE BEARING BEARING, THRUST SWINGARM PIVOT OUTER SEAL SWINGARM PIVOT INNER SEAL TOP-HAT WASHER, BUFFER, M6 DRIVE CHAIN GUIDE BLOCK WASHER, REAR AXLE NUT, REAR AXLE BRAKE LINE GUIDE - FRONT BRAKE LINE GUIDE - REAR REAR AXLE BLOCK AXLE, REAR WHEEL SWINGARM WELDMENT DRIVE CHAIN GUIDE SHELL SWINGARM BUFFER SWINGARM PIVOT OUTER SPACER SWINGARM PIVOT INNER SPACER REAR AXLE ADJUSTER BLOCK SWINGARM PIVOT BOLT COTTER PIN, 4X36 FLAT WASHER, M14 X FLANGE-HEAD BOLT, M6X40 - NYLOK X X X X X FLANGE-HEAD BOLT, M6X50 - NYLOK FLANGE-HEAD BOLT, M6X12 NUT, HEX FLANGE, M8 NUT, HEX FLANGE, M6 PHILLIPS HD SCREW, M6X16, NYLOK PHILLIPS HD SCREW, M5X8, NYLOK THREADED INSERT, M6 LOCKNUT, M14 X 1. 5 SWINGARM BEARING & SEAL KIT X S E EA ER C DESCRIPTION MODEL INCLUDED IN 5000814 INCLUDED IN 5000814 INCLUDED IN 5000814 INCLUDED IN 5000814 INCLUDED IN 5000814 INCLUDED IN 5000814 FOR USE w /o CHAIN GUIDE SHELL INCLUDED IN 252-5002104 INCLUDED IN 252-5002104 NOTES SWINGARM PARTS LIST 24 Rear Shock 1 2 3 4 3 2 1 7 8 9 10 11 5 6 10 15 17 12 14 * 15 16 13 5002426 5000059 5000060 5000061 5001431 5001432 17 1 5002153 16 1 5002154 15 2 5002191 * 1 5002618 * 1 5002620 * 1 5002622 * 1 5002524 14 1 5002601 13 1 5000065 12 1 SEE TABLE 11 1 5001299 10 2 5001298 9 1 5001296 8 1 5000064 7 1 5001295 6 1 5001330 5 1 5001331 4 2 5001291 3 2 5001288 2 4 5001289 1 4 5002220 ITEM QTY DEALER PART NO REQD NUMBER RR SHOCK SPG - 90 N/mm RR SHOCK SPG - 95 N/mm RR SHOCK SPG - 100 N/mm RR SHOCK SPG - 105 N/mm RR SHOCK SPG - 110 N/mm RR SHOCK SPG - 115 N/mm ADDITIONAL PARTS TABLE FHB, M12X61 mm FHB, M12X73 mm FLANGED LOCKNUT, M12 X REAR SHOCK ABSORBER, CR X REAR SHOCK ABSORBER, ER REAR SHOCK ABSORBER, E XX X REAR SHOCK ABSORBER, S X REAR SHOCK ABSORBER, X SHOCK SPRING RETAINER REAR SHOCK SPRING SHOCK SPRING SLEEVE SHOCK SPRING SLEEVE CIRCLIP SHOCK SPRING SEAT WASHER SHOCK SPRING SEAT SHOCK SPG PRELOAD LK RG RESERVOIR BODY OHLINS DCL RESERVOIR BODY WRNG DCL SHOCK MOUNT BEARING SHOCK MOUNT BEARING CIRCLIP SHOCK MOUNT BEARING SEAL SHOCK EYELET BUSHING, 12mm X S E EA ER C DESCRIPTION MODEL NOTES REAR SHOCK PARTS LIST 25 Seat & Number Plates 1 9 2 11 18 15 * 5 6 3 10 12 13 * 14 19 17 16 8 7 4 19 2 5001514 18 4 5001612 17 2 5000095 16 2 5000777 * 1 5002091 15 1 5002613 * 1 5002090 14 1 5002612 13 4 5001013 12 4 5001531 11 1 5002251 10 1 5002089 9 1 5002088 8 1 5002229 7 4 5000141 6 1 5002223 5 1 5002225 4 1 5002226 3 1 5002227 * 1 5002609C 2 1 5002610C * 1 5002609 * 1 5002527 1 1 5002610 ITEM QTY DEALER PART NO REQD NUMBER X X X X XX XX XX XX X XX X X XX X X X XX X S E EA ER C MODEL TOP-HAT WASHER PHILIPS HEAD SCREW, M6X12 mm FHB, M6X20 mm ISOLATION STRIP, 55 X 25. 4 mm SHROUD, R SLV SHROUD, R, SLV, WIDE SHROUD, L SLV SHROUD, L, SLV, WIDE FHB, M6X16 mm TOP-HAT WASHER HEAT SHIELD LEFT NUMBER PANEL - WHITE RIGHT NUMBER PANEL - WHITE PUSH NUT, ZINC BHCS, M6X12 mm SEAT LATCH MOUNT SEAT LATCH HOOK SEAT LATCH SPRING SEAT LATCH PIN SEAT COVER, BLK/YELLOW SEAT COVER, BLK/RED SEAT ASSEMBLY, BLK/YELLOW SEAT ASSEMBLY, BLK/RED, MOTARD SEAT ASSEMBLY, BLK/RED DESCRIPTION NOTES SEAT & PLASTIC PARTS LIST 26 Frnt Fender & Frnt Number Plte 13 14 * 15 16 11 12 10 2 1 4 7 8 1 9 4 3* 5 6 5 2 18 18 2 5001512 17 2 5000095 16 1 5002453B 15 1 5002453 * 2 5002392 14 2 5002390 13 1 5002212 12 1 5002391 11 1 5002393 10 1 5002213 9 2 5001013 8 2 5002292 7 1 5002087-01 6 4 5001013 5 6 5000192 4 5 5001514 * 1 5002525 * 1 5002259 3 1 5002093 2 3 5001184 1 1 5002092 ITEM QTY DEALER PART NO REQD NUMBER XX XX X X X X XX X XX X X X S E EA ER MODEL FENDER NUT, M6 FLANGE-HEAD BOLT, M6X20 - NYLOK BULB, HEADLIGHT HEADLIGHT BULB, HEADLIGHT, 38 DEGREE BEAM BULB, HEADLIGHT, 10 DEGREE BEAM HEADLIGHT BULB, TAILLIGHT LENS, TAILLIGHT TAILLIGHT ASSEMBLY FLANGE-HEAD BOLT, M6X16 - NYLOK SPACER, REAR FENDER REAR FENDER, SILVER FHB, M6X16 mm FLAT WASHER, M6 TOP-HAT WASHER FRONT FENDER, SILVER, MOTARD FRONT FENDER, SILVER, E X FRONT FENDER, SILVER FHB, M6X12 mm FRONT NUMBER PLATE - WHITE C DESCRIPTION NOTES FENDERS & LIGHTS PARTS LIST 27 Battery Plate 29 25 3 15 7 27 16 9 13 28 10 18 5 6 22 23 17 14 20 8 26 4 24 1 2 19 13 11 12 30 21 30 1 5001374 29 1 6000314 28 1 5001013 27 1 5002362 26 1 6000504 25 1 5002603 24 2 5002148 23 1 5001962-02 22 4 5001184 21 1 5000434 20 4 5001512 19 1 5001514 18 2 5001241 17 4 5001584 16 2 5001561 15 2 5001562 14 2 5001944 13 2 5000192 12 2 5000095 11 1 5002268 10 1 5001240 9 1 472-5001951 8 1 5002280 7 1 5001794 6 1 5001435 5 1 5000887 4 1 5002255 3 1 5002217-01 2 1 5002267 1 1 5002190-02 ITEM QTY DEALER PART NO REQD NUMBER X SPACER, 16X8. 4X3. 2 mm NUT, LOCK, M6 FHB, M6X16 mm BATTERY BOLT/NUT KIT, M/C BHCS, M6X20 mm, ZINC, NYLOCK MAIN POWER RELAY BOLT, M6X12 BRASS STARTER SOLENOID FHB, M6X12 mm NUT, HEX FLANGE, M6 FENDER NUT, M6, SQUARE TOP HAT WASHER RIVET WASHER WASHER, M5 WASHER, M5 LOCKNUT, M5 FHB M5X25 mm, ZINC FLAT WASHER, M6 FHB, M6X20 mm BHCS, M6X10 mm, ZINC FUSE HOLDER RIVET ELECTRONIC CONTROL MODULE BATTERY WASHER, LOCK, 10 FUSE HOLDER FUSE, 10 AMP BUS BAR BATTERY STRAP MUD FLAP BATTERY PLATE DESCRIPTION SPECIFY MODEL WHEN ORDERING 2 PER PKG X S E EA ER C MODEL NOTES BATTERY PLATE PARTS LIST 28 Electrical 5 2 6 9 4 1 8 7 3 9 2 5001946 8 1 5002309 7 1 5002455 6 1 5000434 5 1 5000011 4 1 5002218 3 1 5002049 2 1 5002216 1 1 5002602 ITEM QTY DEALER PART NO REQD NUMBER XX FHB M6X30 mm, ZINC X LIGHTING CAP SEAL XXX HARNESS CONNECTOR, LIGHTING NUT, HEX FLANGE, M6 STARTER MOTOR 12V 0. 65KW STARTER MOTOR CABLE POSITIVE BATTERY CABLE NEGATIVE BATTERY CABLE MAIN WIRE HARNESS X S E EA ER C DESCRIPTION MODEL NOTES ELECTRICAL PARTS LIST 29 Exhaust 7 1 3 5 6 2* 8 4 8 4 5001605 7 2 5001345 6 1 5000612 5 1 5000095 4 2 5002265 3 1 5002209 * 1 5002082 2 1 5002242 1 1 5002083 ITEM QTY DEALER PART NO REQD NUMBER NUT, HEX FLANGE, M6-12PT EXHAUST CRUSH WASHER FHB, M8X35 mm FHB, M6X20 mm GROMMET, EXHAUST SPRING, EXHAUST X X X X EXHAUST, SILENCER XX EXHAUST, SILENCER EXHAUST, HEADER PIPE X S E EA ER C DESCRIPTION MODEL NOTES EXHAUST PARTS LIST 30 Radiator 17 7 11 12 3 16 4 1 * 11 9 15 14 10 5 13 12 11 2 7 * 18 6 8 18 1 5000484 17 2 5000093 16 1 5000793 15 1 5002145-03 14 1 5002044 13 4 5000543 12 4 5000719-03 11 6 5000192 10 2 5000323 9 2 5001184 8 2 5000350 7 4 5000178 6 1 5001511 5 1 5002147 4 1 5002146 3 1 5000542 * 1 5002079 2 1 5002611 * 1 401-5002080 1 1 401-5002347 ITEM QTY DEALER PART NO REQD NUMBER O-RING, 2-013 FHB M6X25 mm HOSE CLAMP, 5. 6MM - 16mm HOSE, COOLANT BLEED RADIATOR OVERFLOW TUBE HOSE CLAMP, 14-27mm TP-HT WASHER FLAT WASHER, M6 TINNERMAN CLIP FLANGE-HEAD BOLT, M6X12 - NYLOK FHB, M6X25 mm GROMMET, 3/8 ID RADIATOR DRAIN PLUG COOLANT HOSE, RAD TO WATER PUMP COOLANT HOSE, RAD TO OUTLET CVR RADIATOR CAP X RADIATOR GUARD X X X X X RADIATOR GUARD, WIDE X RADIATOR X X X X X RADIATOR, WIDE X S E EA ER C DESCRIPTION MODEL NOTES RADIATOR PARTS LIST 31 Airbox 5 16 17 13 1 14 14 6 8 15 18 3 4 10 2 11 12 7 9 18 1 5000793 17 1 5002331 16 1 5001922 15 1 5001595 14 2 5000962 13 1 5002529 12 5000487 1 11 1 5000403 10 5001149 1 9 2 5002293 8 2 5000178 7 2 5000350 6 1 5002152 5 1 5002150 4 6 5001238 3 2 5001239 2 1 5002138 1 1 603-5002149-03 ITEM QTY DEALER PART X S E EA ER C NO REQD NUMBER MODEL HOSE CLAMP, 5. 6mm - 16mm HOSE, BREATHER, FRAME TO ARIBOX VACUUM HOSE, 5/32" ID 265 mm VACUUM HOSE, 5/32" ID 609 mm VACUUM HOSE, 5/32" ID 185 mm 4-WAY FITTING, VACUUM HOSE O-RING, 2-012 AIR TEMPERATURE SENSOR CLAMP, BAND TOPHAT, AIRBOX GROMMET, 3/8 ID FHB, M6X30, mm AIR FILTER CLIP AIR FILTER RIVET AB4-6CLD INTAKE END RETAINING RING AIR FUNNEL AIRBOX DESCRIPTION TO PRESSURE REGULATOR TO ECU (1) TO ENGINE & (1) TO AIRBOX INCLUDED IN 603-5002149-03 INCLUDED IN 603-5002149-03 INCLUDED IN 603-5002149-03 NOTES AIRBOX PARTS LIST 32 Fuel Tank 7 5 9 8 13 9 1 * 6 3 2 * 4 11 14 12 10 14 2 5000799 13 2 5000765 12 4 5000192 11 2 5000862 10 2 5000802 9 3 5000137 8 1 5002398 7 1 5000175 6 1 5000873 5 1 5000169-01 4 1 5001778 * 1 5002270 3 1 5002417 2 2 5002140-02 * 1 351-5002074 1 1 351-5002244 ITEM QTY DEALER PART NO REQD NUMBER XX XX X XXX XX X S E EA ER C MODEL TOP-HAT WASHER, FUEL TANK TAB TOP-HAT WASHER FLAT WASHER, M6 FLNG HD BLT, M6X40 mm GROMMET, FUEL TANK FHCS, M6X16 ZINC SEAT CATCH FUEL TANK BREATHER HOSE FUEL TANK CAP GASKET FUEL TANK CAP FUEL PICKUP FILTER FUEL PICKUP TUBE FUEL PICKUP TUBE FUEL TANK FEMALE QUICK CONNECT FUEL TANK FUEL TANK DESCRIPTION INCLUDED IN FUEL TANK INCLUDED IN FUEL TANK INCLUDED IN FUEL TANK INCLUDED IN FUEL TANK NOTES FUEL TANK PARTS LIST 33 Fuel System 21 24 23 22 18 30 19 8 9 5 2 27 28 17 16 15 29 26 11 10 31 4 1 25 12 3 14 13 7 6 20 31 2 5002410 30 1 5001137 29 1 5001544 28 2 5001578 27 2 5001579 26 1 5000395 25 1 5000836 24 6 5001607 23 1 5002205-05 22 1 5002204-05 21 1 5002203-05 20 1 5002202-05 19 1 5002201-02 18 2 5002141-02 1 5000544 17 16 2 5000793 15 2 5001789 14 3 5000434 13 1 5001184 12 2 5000093 11 1 5002327 10 1 5002328 9 4 5001549 8 2 5001502 7 2 5001641 6 2 5001642 5 2 5001501 4 1 5002604 3 1 5002124 2 1 5002075 1 1 5000168 ITEM QTY DEALER PART X S E EA ER C NO REQD NUMBER MODEL INSULATING BOOT O-RING, 008 FUEL REGULATOR HOUSING - PLASTIC GROMMET, FUEL REGULATOR TOP-HAT WASHER FUEL PRESSURE REGULATOR INTERNAL RETAINING RING, 36mm OETIKER HOSE CLAMP, 12. 3mm HOSE, FUEL, REGULATOR TO TANK HOSE, FUEL, INJECTOR TO REGULATOR HOSE, FUEL, PUMP TO INJECTOR HOSE, FUEL, FILTER TO PUMP HOSE, FUEL, TANK TO FILTER FUEL TANK MALE BARBED INLET FUEL FILTER HOSE CLAMP, 5. 6-16 mm HOSE CLAMP, 37-51 mm NUT, HEX FLANGE, M6 FLANGE-HEAD BOLT, M6X12 - NYLOK FLANGE-HEAD BOLT, M6X25 - NYLOK ISOLATION STRIP, 6. 4X30 mm ISOLATION STRIP, 3. 2X30 mm WASHER, CRUSH, ALUMINUM BANJO BOLT NUT, HEX, 6-32 WASHER, SERRATED, NO. 6 ZINC BANJO FITTING FUEL PUMP PIGTAIL FUEL PUMP GUARD FUEL PUMP MOUNT FUEL PUMP DESCRIPTION MALE FUEL FITTING NOTES FUEL SYSTEM PARTS LIST 34 Decals 1 6* 8* 3* 9* * 2* 7* 5* 4* 5* 11 10 11 1 5002626-R 10 1 5002627 9 1 5002238 * 5002646 8 5002633 * 1 5002625 7 1 5002626 * 1 5002645 6 1 5002632 * 1 5002643 * 1 5002644 * 1 5002630 5 5002631 * 1 5002641 * 1 5002642 * 1 5002636 * 1 5002637 * 1 5002628 4 1 5002629 * 1 5002634 3 1 5002635 * 1 5002649 * 1 5002648 * 1 5002647 * 1 5002640 * 2 5002531 2 2 5002623 1 1 5002624 ITEM QTY DEALER PART NO REQD NUMBER X X XX X XX XX XX XX XX XX XX XX XX X X X X XX XX XX XX XX X X X X X X X S E EA ER C MODEL DCL, E440A GP, NMBR PLT, REVLOC DCL, E440A GP, NMBR PLT, BLK, R DCL, PREM FUEL DCL, C LOGO, BLK/YEL DCL, C LOGO, BLK/RED DCL, GP, NMBR PLT, BLK, L DCL, GP, NMBR PLT, BLK, R DCL, CDALE, FK GRD, BLK/YEL DCL, CDALE, FK GRD, BLK, SET DCL, SHROUD FADE, YEL, L DCL, SHROUD FADE, YEL, R DCL, SHROUD FADE, L DCL, SHROUD FADE, R DCL, CDALE/C, BLK/YEL, L, SET DCL, CDALE/C, BLK/YEL, R, SET DCL, CDALE/C, BLK, S440, L, SET DCL, CDALE/C, BLK, S440, R, SET DCL, CDALE/C, BLK, L, SET DCL, CDALE/C, BLK, R, SET DCL, CDALE/FLAG, SWINGARM L DCL, CDALE/FLAG, SWINGARM R DCL, C440R, RR FDR, BLK/RED DCL, E440R, RR FDR, BLK/RED DCL, E440A, RR FDR, BLK/YEL DCL, E440, RR FDR, BLK/YEL DCL, S440, RR FDR, BLK DCL, X440, RR FDR, BLK/RED DCL, GRAPHIC, RR FDR DESCRIPTION NOTES DECALS PARTS LIST 35 Vehicle Warnings (1) (3) (1) (2) (2) (4) (3) (4) * - Any replacement warning label can be obtained by vehicle owner's free of charge by calling 1-800-MOTO-USA. 4 1 5001371-01 3 1 5000418 2 1 5001262-01 1 1 5000266-01 ITEM QTY DEALER PART NO REQD NUMBER WRN, FRAME DECAL, USE DECAL, DISCLAIM WRN, MULTI X S E EA ER C MODEL DESCRIPTION NOTES WARNINGS PARTS LIST 36 [. . . ] [. . . ]